Facade panel with integrated window system

ABSTRACT

A prefabricated construction element for use in construction of multi-storey buildings. The construction element is a mass timber exterior wall panel, integrating building assemblies such as windows, exterior wall finishes, and connectors to other building components. The construction element comprises: an envelope subpanel; a feature element such as a window or door; an insulation layer; and a cladding layer, wherein the envelope subpanel comprises an upper beam along its top edge and a lower beam along its bottom edge, and a plurality of spacers disposed between the upper beam and the lower beam, defining one or more openings for receiving the feature element; wherein the insulation layer is attached to the envelope subpanel and provided with one or more openings corresponding to the feature element; wherein the cladding layer overlies the insulation layer and is attached thereto.

FIELD OF THE INVENTION

The present invention relates to the field of construction of modular structures. More particularly, the present invention relates to the field of panel systems for use in the construction of mass timber multi-storey, modular structures.

BACKGROUND OF THE INVENTION

Prefabricated façade wall panels are becoming increasingly commonly used in construction (for example in the construction of curtain walls for multi-storey modular buildings) due to efficiency factors—often leading to possible reductions in terms of construction time and/or construction costs. Prefabricated façade panels generally allow for very quick assembly during the construction process. This can, for example, allow for a quick building envelope enclosure, which among various advantages, can reduce the risk of water damage to the overall structure (e.g. caused by rain).

Using prefabricated façade panels in construction can be relatively straightforward when the façade panels are used simply to construct basic wall sections without windows/door or other such features. However, when it comes to using prefabricated façade panels to construct wall sections that also have windows, doors or other complications, additional complexities and considerations will apply.

Curtain wall systems are usually made from steel or timber as frame constructions from many small elements. (Mass timber is increasingly being used in the manufacture of prefabricated façade panels for a number of reasons, including because it is generally considered to be environmentally sustainable and of relatively low cost). The cavities between the frames are usually filled with insulation and covered with wooden boards. The complexity of this construction makes it difficult to adapt to different window sizes and difficult to ensure air-tightness along all seams.

Further, many of the disciplines associated with such building materials, such as steel framing, mass timber construction, wall finishes, connectors, insulation and window manufacturing have become increasingly specialised and separated, resulting in high tolerance margins and limited adaptability; the separation of these building materials disciplines, make it challenging to integrate such disciplines to develop prefabricated façade panels. Largely because of these reasons, prefabricated façade panels have not generally been used in the construction of wall sections having windows, doors or other complication features, for multi-storey modular buildings.

On a typical such construction project, the windows, doors, connection hangers for insulation and various other building components are done on-site. The mass timber façade panels and such building components are fastened/installed in weather-permitting (sometimes challenging) conditions. These discrete trades arrive on-site and conduct their work according to the generalized instructions from manufacturers and the architectural specifications. When components, membranes, cladding, etc. are attached, the materials themselves may be exposed to the weather and material expansion differentials, which can lead to poor constructability.

Accordingly, it is contemplated that there could be significant advantages to be had in providing for a construction element wherein façade panels and such building components are integrated together and prefabricated, and in providing a construction system utilising such prefabricated façade panels.

SUMMARY OF THE INVENTION

In accordance with an aspect of the present invention, disclosed herein is a prefabricated façade panel (sometimes generally referred to herein as a construction element) having an integrated window system. Such a façade panel and integrated window system may have particular application for use in the construction of curtain walls for multi-storey, modular structures or buildings. Also disclosed herein is a system for constructing a multi-storey building or modular structure using such façade panels. Also disclosed herein is a method of constructing such a façade panel having integrated windows.

Disclosed herein is a composite construction element for building multi-storey structures, which construction element is prefabricated and is to be fastened/installed on the construction site.

In accordance with an aspect of the present invention, disclosed herein is an integrated construction element for constructing a curtain wall for a multi-storey building, comprising: an envelope structural subpanel; one or more feature elements; an insulation layer; and a cladding layer, wherein the envelope structural subpanel, has a top edge and a bottom edge, and comprises an upper beam disposed substantially along the top edge and a lower beam disposed substantially along the bottom edge, and a plurality of spacers disposed between the upper beam and the lower beam, wherein the upper beam, lower beam and plurality of spacers define one or more openings for receiving the one or more feature elements; wherein the insulation layer is attached to the envelope structural subpanel, and wherein the insulation layer is provided with one or more openings corresponding to the feature elements; wherein the cladding layer overlies the insulation layer and is attached thereto.

In one aspect, the feature elements may be windows, doors or combinations thereof. In another aspect, the construction element additionally comprises a plurality of attachment means (such as a clip and cleat system or a bracket system) connected to the envelope structural subpanel for attaching the construction element to a floor or ceiling of a building.

In accordance with another aspect, the construction element may additionally comprise a plurality of strapping elements for keeping the insulation layer in place. In accordance with one aspect, the envelope structural subpanel of the construction element is made substantially from mass timber. In accordance with another aspect, the spacers abut the upper beam and lower beam. In yet another aspect, the construction element may additionally comprise an engagement means in the form of a tongue-and-groove joint, comprising either a tongue or groove disposed substantially along either or both of a top edge of the construction element and/or of a bottom edge of the construction element, wherein each tongue or groove, as the case may be, of the construction element is adapted to matingly engage with a corresponding groove or tongue of a second construction element, when the second construction element is disposed vertically adjacent to the construction element, thereby facilitating the engagement of the construction element with the second construction element. In yet another aspect, the engagement means may be in the form of a “chicken head” joint, as is known in the art.

In another aspect, the construction element may additionally comprise one or more integrated building features for providing the multi-storey building with a soffit; a setback, a balcony, a parapet, a canopy, railings or combinations thereof.

In accordance with another aspect of the present invention, disclosed herein is a system comprising a plurality of such construction elements installed on a multi-storey building in a grid-like configuration, wherein a first of the construction elements is provided with one or more connectors disposed proximate to a periphery thereof, wherein the connectors secure the first construction element to a second construction element that is disposed horizontally or vertically adjacently thereto.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of an exemplary embodiment of the composite façade panel of the present invention.

FIG. 2 is a partially-exploded perspective view of the composite façade panel, in accordance with one aspect of the present invention.

FIG. 3 is a partially-exploded perspective view of another embodiment of the composite façade panel, in accordance with another aspect of the present invention.

FIG. 4 is a perspective view of one embodiment of the envelope structural subpanel, in accordance with an aspect of the present invention.

FIG. 5 is a perspective view of another embodiment of the envelope structural subpanel, in accordance with an aspect of the present invention.

FIG. 6 is a partially-exploded perspective view illustrating a plurality of composite façade panels being installed upon a plurality of floor slabs of a multi-storey building.

FIG. 7 is a perspective view illustrating various other composite façade panels having various additional features.

FIG. 8 is a side view illustrating the engagement of vertically adjacent composite façade panels.

FIG. 9 is a side view illustrating the configuration of several composite façade panels across several floors of a multi-storey building.

DETAILED DESCRIPTION OF THE INVENTION

A detailed description of one or more embodiments of the present invention is provided below along with accompanying figures that illustrate the principles of the invention. As such, this detailed description illustrates the present invention by way of example and not by way of limitation. The description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations and alternatives and uses of the invention, including what is presently believed to be the best mode and preferred embodiment for carrying out the invention. It is to be understood that routine variations and adaptations can be made to the invention as described, and such variations and adaptations squarely fall within the spirit and scope of the invention. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.

Disclosed herein is a composite construction element for building multi-storey structures. More specifically, disclosed herein is a mass timber composite construction element for use in constructing a curtain wall for a multi-storey structure, which construction element is prefabricated and is to be installed/connected on the construction site. The composite construction element is generally described and illustrated herein for use in the construction of a curtain wall for a multi-storey building (i.e. as a “new build”); however, it will be appreciated by one skilled in the art that the composite construction element may also be used (or adapted for use) in the construction of a curtain wall to retrofit an existing multi-storey building.

Referring to FIG. 1, this illustrates an exploded perspective view of an exemplary embodiment of the composite façade panel of the present invention. The composite façade panel 10 comprises an envelope structural subpanel 20 and a window subpanel system 30. The window subpanel 30 comprises the elements that typically make up a curtain wall having windows, namely: one or more windows 32; an insulation layer 34, which includes one or more corresponding openings for receiving the one or more windows 32; strapping 36; and a cladding layer 38. Alternative configurations of the components of the window subpanel 32 are of course possible. It is also contemplated that the other component layers may be substituted or supplemented depending on the specific requirements, functionality or desired specifications for the curtain wall, as will be understood by one skilled in the art. For example, additional layers of a vapor barrier, waterproofing, additional insulation, additional cladding may be added to, or used to replace one or more of the component layers, as may be appropriate in particular circumstances. While not specifically illustrated in FIG. 1, it is also contemplated that such a composite façade panel may optionally additional incorporate one or more door elements, e.g. where the composite panel is used to construct a wall section for a building (i.e. rather than a curtain wall section). In a similar fashion as discussed above that a prefabricated composite façade panel can be provided that has one or more windows integrated therein, so a prefabricated composite façade panel can also be provided with an integrated door or doorway, and/or windows. It is contemplated that other complications may also be integrated into such a composite façade panel (such as electrical services and mechanical services, venting structures, etc.), as might typically be found in a multi-storey building.

It will be evident to one skilled in the art that such a prefabricated, integrated façade panel system as disclosed herein will provide for advantages in general airtightness. There will generally be minimal tolerances between the various component layers (e.g. given the integrated membranes) and the ease of on-site assembly will generally reduce errors and improve quality control issues that might otherwise be caused by variations in on-site workmanship and/or caused by difficult on-site work conditions during installation of the various component layers.

The composite façade panel 10 is also provided with an attachment means 40, for affixing the composite façade panel 10 to the structure of the building. In one embodiment, the attachment means 40 may be in the form of a clip and cleat system or a bracket system (as is known in the art), by means of which a façade panel 10 may be installed or hung onto an upper floor, such that the façade panel 10 extends down one or more floors of the building. (For example, the attachment means 40 can be configured to attach to the upper floor near the underside of the ceiling of the upper floor or near the topside of the floor or the upper floor).

As mentioned above, the composite façade panel 10 is a unitary, prefabricated panel.

Referring to FIG. 2, this shows a partially-exploded view of the envelope structural subpanel 20 and the window subpanel 30, which together make up the composite façade panel 10. In this example, the windows 32 of the window subpanel 30 are shown as having a regular pattern. The envelope structural subpanel 20 and the window subpanel 30 are affixed together to form the composite façade panel 10, which is a unitary prefabricated construction panel. FIG. 3 illustrates another embodiment of the structural subpanel 20 and window subpanel 31, which together make up the composite façade panel. In this example, the windows 32 in the window subpanel 31 may have an irregular window pattern. Thus, it is to be understood that the present composite façade panel system 10 is readily customizable in order to be adapted to different construction requirements and configurations.

FIG. 4 illustrates an exemplary envelope structural subpanel 20. The envelope structural subpanel 20 comprises an upper subpanel or upper beam 22, disposed at the top of the envelope structural subpanel 20 and extending substantially the length thereof; a lower subpanel or lower beam 24, disposed at the bottom of the envelope structural subpanel 20 and extending substantially the length thereof; and plurality of strengthening infill panels or spacers 26, disposed between the upper beam 22 and lower beam 24. Optionally, these components may be affixed to an internal subpanel 29, such that the components are integrated as a single subpanel. Between the strengthening spacers 26, openings may be provided to correspond with each of the plurality of windows 32. The primary function of the upper beam 22, lower beam 24 and strengthening spacers 26 is to provide structural integrity, shear stiffness, and/or structural support to the envelope structural subpanel 20 of the composite façade panel 10. The upper beam 22 and the lower beam 24 primarily provide structural support in the direction along the length of the envelope structural subpanel, whereas the strengthening spacers 26 primarily function to provide structural support in the direction along the width of the envelope structural subpanel 20. The upper beam 22, lower beam 24 and strengthening spacers 26 may preferably be constructed from mass timber.

FIG. 5 illustrates another possible embodiment of the envelope structural subpanel 20. As shown, in this example, the strengthening spacers 28 abut or may be affixed to the upper beam 22 and lower beam 24. These components may be integrated together into a single subpanel. Optionally, such components may be affixed to an internal subpanel 29 (not shown in FIG. 5).

Referring to FIG. 6, this illustrates a plurality of composite façade panels 10, as they may be installed upon a multi-storey building. Portions of a number of floor slabs 50 of a multi-storey building are shown. For example, a first composite façade panel 12 may be installed on a first floor slab 52, and vertically “hung” from the end of such floor slab, such that the first composite façade panel 12 extends from the floor slab 52 to at least a second floor slab 54, i.e. the floor slab on the floor below, thus forming an external curtain wall between the first floor slab and the second floor slab. In this fashion, composite façade panels may be installed and hung from other floor slabs, thus creating a multi-storey curtain wall for the building. In this manner, the building may be provided with a curtain wall, which is affixed to the structural parts of the building (i.e. the floors), but which is otherwise structurally independent from the building, thus allowing the curtain wall to respond to movements or expansion/contraction of the building or of the façade panels.

Although not specifically illustrated, it is contemplated that the composite façade panels may also be provided with connectors or attachment means for horizontally connecting adjacent composite façade panels, in order to form a grid-like system. Optionally, composite façade panels may also be provided with connectors or attachment means for vertically connecting composite façade panels with other composite façade panels disposed above or below thereto.

It will be apparent that the composite façade panels as described above may be used in a modularized system, for efficient assembly and installation of walls/curtain walls for a multi-storey building. Furthermore, the design of the composite façade panels is such that they can be configured/adapted and customised for different specifications.

The straight composite façade panel 10 described above may be adapted or configured for various other building features or geometries. FIG. 7 illustrates a number of other types of composite façade panels having various additional features. For example, corner façade panel 60 includes a corner section 62, which is used for constructing a portion of a curtain wall corresponding to a corner of a building. Another façade panel 64 may be provided with a soffit panel 66, and used for façade panels where a section of a building has an overhang. Façade panel 64 may also be provided with a setback 68. A façade panel 64 may also be provided with a balcony or parapet panel 70, where construction of a balcony/parapet is required. Other adaptations depending on the specific construction requirement for a particular building will be apparent to one skilled in the art. These façade panel examples will each potentially have the same sort of advantages discussed previously that are applicable to the straight composite façade panel 10; such prefabricated façade panels can be relatively quickly and easily assembled/connected together at a construction site, without requiring multiple specialist trades to each be involved at a construction site.

A composite façade panel may also be optionally provided with a number of external finishes or features, such as rain screens, shading screens (canopies), railings, each of which will be constructed as to be affixed to the envelope structural subpanel 20 of said composite façade panel.

Referring to FIG. 8, this shows the ends of a first floor slab 52 and a second floor slab 54, i.e. the ends of an upper floor and a lower floor of a multi-storey building. A first composite façade panel 12 is shown installed on or “hung” from the first floor slab 52, via an attachment means 40. A second composite façade panel 14 is shown installed on the second floor slab 54, on the floor below. The composite façade panels thus make up a section of curtain wall for the multi-storey building. In one embodiment, a first composite façade panel 12 may also be provided with engagement means on one or both of its top and bottom edges, for engagement with the another corresponding composite panel positioned directly above or below said first composite façade panel 12. As shown in FIG. 8, a first composite panel 12 is provided with tongue joint 74 running along the length of its bottom edge. A second composite façade panel 14 is provided with a corresponding groove 72 running along the length of its top edge, wherein such groove 72 is adapted to receive the tongue 74 of the first composite façade panel. Thus, the first composite façade panel 12 and a corresponding second composite façade panel 14 may be matingly engaged to provide additional stability between the composite façade panels. Such interlocking façade panels may be weather-stripped to seal to one another. One other advantage of such a tongue-and-groove-type joint is that it can account for small thermal expansion/contraction effects or other movement effects, in or between the composite façade panels (e.g. caused by temperature changes, inter-storey differential movement, concrete creep, column foreshortening and/or seismic movement). For example, in the event a façade panel expands in the vertical direction, there is generally sufficient “play” within the gap between the tongue and groove joint to permit such expansion.

Besides the tongue-and-groove-type joint described above, other engagement means, that are known in the art, may be used for engaging a façade panel with another façade panel, whether directly thereabove, therebelow or adjacent thereto. For example, a simple butt joint closed off with a gasket around the edges of the façade panels could be used. Another possibility is to use a gutter weather seal which is often referred to in the industry as “a chicken head” detail.

Depending on the circumstances and desired specifications, in other embodiments, a composite façade panel may also be actually attached and secured to another vertically adjacent façade panel, such that a particular composite façade panel does not necessarily need to be attached to or hung from a floor slab so securely (such as using the attachment means). An example of such a curtain wall configuration is illustrated in FIG. 9. A third façade panel 16 is engaged with and attached to a second façade panel 14, such that it does not need to be secured in quite the same fashion to a third floor slab 56. 

What is claimed is:
 1. An integrated construction element for constructing a curtain wall for a multi-storey building, comprising: an envelope structural subpanel; one or more feature elements; an insulation layer; and a cladding layer, wherein the envelope structural subpanel, has a top edge and a bottom edge, and comprises an upper beam disposed substantially along the top edge and a lower beam disposed substantially along the bottom edge, and a plurality of spacers disposed between the upper beam and the lower beam, wherein the upper beam, lower beam and plurality of spacers define one or more openings for receiving the one or more feature elements; wherein the insulation layer is attached to the envelope structural subpanel, and wherein the insulation layer is provided with one or more openings corresponding to the feature elements; and wherein the cladding layer overlies the insulation layer and is attached thereto.
 2. The construction element of claim 1, wherein the feature elements are windows, doors or combinations thereof.
 3. The construction element of claim 1, additionally comprising a plurality of attachment means connected to the envelope structural subpanel for attaching the construction element to a floor or ceiling of a building.
 4. The construction element of claim 3, wherein the attachment means consists of a clip and cleat system.
 5. The construction element of claim 3, wherein the attachment means consists of a bracket system.
 6. The construction element of claim 1, additionally comprising a plurality of strapping elements for keeping the insulation layer in place.
 7. The construction element of claim 1, wherein the envelope structural subpanel is made substantially from mass timber.
 8. The construction element of claim 1, wherein the spacers abut the upper beam and lower beam.
 9. The construction element of claim 1, additionally comprising an engagement means disposed substantially along one or both of a top edge of the construction element and a bottom edge of the construction element, wherein the engagement means is adapted to matingly engage with a second construction element, when said second construction element is disposed vertically adjacent to the construction element, thereby facilitating the engagement of the construction element With the second construction element.
 10. The construction element of claim 9, wherein the engagement means is a tongue-and-groove joint comprising: a tongue or groove disposed substantially along one or both of a top edge of the construction element and/or of a bottom edge of the construction element; and a corresponding groove or tongue, as the case may be, disposed on an edge of the second construction element.
 11. The construction element of claim 9, wherein the engagement means is a chicken head joint.
 12. The construction element of claim 1, additionally comprising one or more integrated building features for providing the multi-storey building with one or more selected from the group consisting of: a soffit; a setback, a balcony, a parapet, a canopy and railings.
 13. A system comprising a plurality of the construction elements of claim 1 installed on a multi-storey building in a grid-like configuration, wherein a first of the plurality of construction elements is provided with one or more connectors disposed proximate to a periphery thereof, wherein the connectors secure the first construction element to a second of the plurality of construction elements that is disposed horizontally or vertically adjacently thereto. 